WESTERN PRODUCTS 7777 NORTH 73RD STREET P.O. BOX 23045 MILWAUKEE, WISCONSIN 53223 -8 ” e T 6 M_ I a A DIVISION OF DOUGLAS DYNAMICS, L.L.C. Refer to the current selection list for minimum vehicle recommendations and ballast requirements. Metric Fasteners Have Blue or Black Chromate Finish 28 ITEM PART NO. 1 61805 2 61810 3 61390 4 61391 8 61642 9 61643 10 61412 11 60495 12 61652 13 61653 17 61806 18 61807 19 61803 20 61804 21 61802 22 61829 25 90020 26 90100 27 90101 28 90128 29 90129 30 90130 35 91102 36 91105 37 91106 Vehicle Installation Instructions and Parts List Model 1295 Mount Assembly Box No. 61820 Ford F-250/F-350 4 x 4, F-250/350 2WD (Over 8,500 GVWR), Super Duty 1992 & Later Hydraulics Box No. 56365 Harness Kit No. 61590 December 1,1996 Mount Assembly Box No. 61820 PARTS DIAGRAM & LIST 3’ 26 QTY. DESCRIPTION 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 1 4 16 2 10 2 2 4 6 6 MOUNT FRAME 1265,1275,1295 THRUST FRAME SPREADER DR SPREADER CU MOUNT DR MOUNT CU LINK ARM EVAPORATOR BRACKET NUT BAR DR NUT BAR CU GUSSET, LONG DR GUSSET, LONG CU GUSSET, SHORT DR GUSSET, SHORT CU SHIM DR SHIM CU 5/16-18X1 HX CS G2 ZP 112-13X1-112 HX CS G5 ZYC 112-13X1-314 HX CS G5 ZP 518-l 1X1-3/4 HX CS G5 ZP 5/8-l 1X2 HX CS G5 ZP 518-l 1X2-1/4 HX CS G5 ZP 5/16 PLAIN WASHER TY A STD ZP 112 PLAIN WASHER TY A STD ZYC 5/8 PLAIN WASHER TY A STD ZP ITEM PART NO. 38 91205 45 91332 46 91335 47 91337 49 91911 50 93062 Not Shown 56080 61536 62313 91055 91056 91119 QTY. 8 4 10 14 2 2 DESCRIPTION 112 SP LK WASHER ZYC 5/16-18 PT HX LK NUT NYIS ZYC l/2-13 PT HX LK NUT NYIS ZYC 5/8-l 1 PT HX LK NUT NYIS ZYC 5/32X1-112 COTTER PIN ZYC RIVET 3/4” X3-1/4” G5 ZYC DASH BRACKET CABLE TIE - LONG 5/8 ID X 3”LG CONVOLUTED TUBE M6-1.99X25 HXW CS G8.8 M6-1 .OO HX NUT 3/16 SPECIAL PLAIN WASHER Parts listed above may be found in the following assembly 61826 1 BOLT BAG ASSY (61820) Abbreviations ASSY Assembly ID Inside Diameter SP Spring CS Cap Screw LG Long STD Standard CU Curb-Side LK Lock TY Type DR Driver-Side MM Millimeter ZP Zinc Plate G Grade NYIS Nylon Insert ZYC Zinc Yellow HX Hex OD Outside Diameter Chromate HXW Hex Washer PT Prevailina Toraue This product is manufactured underthe following patents: 4,280,062,5,420,480,5,125,t74, and 4,999,935. The following are registeredBand unregisteredTM trademarks of Douglas Dynamics, L.L.C.: WESTERN@ , ISARMATIC@ , Hydra-Turn@ , UniMountB , Roll-ActionTM , and PRO-GUARDTM Western reserves the right under its Product Improvement Policy to change construction details and furnish equipment when so altered without reference to illustrations or specifications used herein. Form No. t 3601 -l- Prlnted in U.S.A.
Transcript
WESTERN PRODUCTS 7777 NORTH 73RD STREET
P.O. BOX 23045 MILWAUKEE, WISCONSIN 53223
-8 ” e T 6 M_ I a A DIVISION OF DOUGLAS DYNAMICS, L.L.C.
Refer to the current selection list for minimum vehicle
recommendations and ballast requirements.
Metric Fasteners Have Blue or Black Chromate Finish
Model 1295 Mount Assembly Box No. 61820 Ford F-250/F-350 4 x 4, F-250/350 2WD (Over 8,500 GVWR), Super Duty 1992 & Later Hydraulics Box No. 56365 Harness Kit No. 61590 December 1,1996
MOUNT FRAME 1265,1275,1295 THRUST FRAME SPREADER DR SPREADER CU MOUNT DR MOUNT CU LINK ARM EVAPORATOR BRACKET NUT BAR DR NUT BAR CU GUSSET, LONG DR GUSSET, LONG CU GUSSET, SHORT DR GUSSET, SHORT CU SHIM DR SHIM CU 5/16-18X1 HX CS G2 ZP 112-13X1-112 HX CS G5 ZYC 112-13X1-314 HX CS G5 ZP 518-l 1X1-3/4 HX CS G5 ZP 5/8-l 1X2 HX CS G5 ZP 518-l 1X2-1/4 HX CS G5 ZP 5/16 PLAIN WASHER TY A STD ZP 112 PLAIN WASHER TY A STD ZYC 5/8 PLAIN WASHER TY A STD ZP
DASH BRACKET CABLE TIE - LONG 5/8 ID X 3”LG CONVOLUTED TUBE M6-1.99X25 HXW CS G8.8 M6-1 .OO HX NUT 3/16 SPECIAL PLAIN WASHER
Parts listed above may be found in the following assembly 61826 1 BOLT BAG ASSY (61820)
Abbreviations
ASSY Assembly ID Inside Diameter SP Spring CS Cap Screw LG Long STD Standard CU Curb-Side LK Lock TY Type DR Driver-Side MM Millimeter ZP Zinc Plate G Grade NYIS Nylon Insert ZYC Zinc Yellow HX Hex OD Outside Diameter Chromate HXW Hex Washer PT Prevailina Toraue
This product is manufactured underthe following patents: 4,280,062,5,420,480,5,125,t74, and 4,999,935. The following are registeredBand unregisteredTM trademarks of
Douglas Dynamics, L.L.C.: WESTERN@ , ISARMATIC@ , Hydra-Turn@ , UniMountB , Roll-ActionTM , and PRO-GUARDTM Western reserves the right under its Product Improvement
Policy to change construction details and furnish equipment when so altered without reference to illustrations or specifications used herein. Form No. t 3601 -l- Prlnted in U.S.A.
Recommended Fastener Torque Chart (Ft.-Lb.)
1-8 300 583 893
Metric Grade 8.8 (Ft.-Lb.)
SiZf2 Torque Size Torque M6 7 M 12 60 M8 17 M 14 95 Ml0 35 M 16 155 These torque values apply to mount assembly fasteners except those noted in the instruction.
MOUNT BARS - DR & CU
1. Remove the bumper, with brackets attached, from the vehicle.
2. Locate the mounts tight to the outside and to the bottom of vehicle frame and against the long protruding rivet. (On vehicles without frame rivets, locate mounts to front edge of l/2” holes in bottom of vehicle frame rails.) Clamp mounts in place.
3. Use mounts as templates to drill four l/2” holes in each side of vehicle frame. Install two nut bars to inside of each vehicle frame rail aligning with drilled holes. Fasten each mount to the nut bars with four i/2” x l-1/2” cap screws and lock washers. Tighten cap screws to corresponding torque chart values.
I Mount Box No. 61820 INSTALLATION INSTRUCTIONS
IMPORTANT: Read instructions before assembling. Finger tighten bolts until instructed to tighten to torque shown in torque chart. Use standard methods and practices when attaching snowplow, including wearing safety glasses during drilling.
AS VIEWED FROM DRIVER SIDE DRILL
” X l-112” BOLT
VEHICLE FRAME
OTRUDING RIVET OR
l/2” HOLE (MUST BE TIGHT TO SIDE AND BOTTOM OF VEHICLE FRAME)
THRUST FRAME AS VIEWED FROM DRIVER SIDE 1. Loosely attach thrust frame to each mount
with one l/2” x l-3/4” bolt, flat washer, and locknut in the outer hole and one 5/8” x 2” bolt, flat washer, and locknut in the inner 0
hole. Install flat washers against slots in 0 mounts. --
_--__-__-__ --’ MOUNT
- --
112” X l-314” BOLT - Outer Hole
5/8” X 2” BOLT -
2. If the vehicle has an evaporator canister that interferes with the mount, remove the canis- ter and install the furnished bracket to the original canister mounting holes using exist- ing fasteners. Secure canister to the rear side of bracket using four furnished 5/i 6” x 1” bolts, flat washers and locknuts. Install flat washers against slots.
ET FRAME Inner Hoie C AUTION: Maintain adequate clearance horizonally and vertically between
hoses, steering linkage at maximum right turn, alternator drives, oil cooler lines, and do not collapse evaporator hose.
Form No. 13601 -2-
MOUNT FRAME
1. On vehicles with transmission cooler located in front of the radiator on the curb side, install a convoluted tube over each cooler line above Y” formed by the cooler lines.
CONVOLUTED MOUNT FRAME CROSS ANGLES
OIL COOLER LINES
AS VIEWED FROM DRIVER SIDE 2. Place mount frame onto vehicle frame horns.
Align large hole in side plates to large holes (or slots) in vehicle frame.
3. Slide a shim into place between vehicle frame and side plates on mount frame. Align large holes and from outside of frame insert a 5/8” x l-3/4” bolt, two flat washers and locknut on each side of vehicle. Install a flat washer against mount frame side plate and against ve- hicle frame.
FRAME- I
SPREADER - DR & CU
1. Position a spreader frame, with link arm lugs to- wards center of vehicle, between each mount frame angle and thrust frame angle. During installation, allow for drop in vehicle height when weight of plow is added. The dis- tance between the center of the coupling lug hole and the level surface should be 9-l/2” to 10-l/2” with plow attached and resting on the level surface. (See Coupling Lug Height Check near the end of these instructions.)
2. On each side of mount frame, insert a: 5/8” x 2-l/4” bolt through the thrust frame, spreader frame, and lower hole of mount frame angle; a 5/8” x l-3/4” bolt through highest hole pos- sible in spreader frame and mount frame angle; and a 5/8” x i-3/4” bolt through hole between link arm lugs and front of mount frame angle.
Loosely retain each bolt with a locknut. Continued on next page.
AS VIEWED FROM DRIVER SIDE
518” X f-3/4” BOLT
LINK ARM LU
SPREADER FRA
COUPLING LUG
9-i/2” TO 10-i/2” PLOW ATTACHED & RESTING
ON LEVEL SURFACE
1 ROAD
Form No. 13601 -3-
GUSSET - DR & CU
1. Installation of gussets is determined by the number of holes in the spreader which are be- low the thrust frame angles.
Attach the widest gusset that will fit to the under- side of each thrust frame angle using two l/2” x 1-l /2” bolts and locknuts.
Attach each gusset to a spreader frame with one or two 5/8” x l-3/4” bolt(s) and locknut(s) on each side of vehicle.
2. Starting with the mount frame to vehicle frame fasteners, tighten all bolts to corresponding torque chart values.
SECURING MOUNT FRAME
1. Use each mount frame side bar as a template to drill two l/2” holes into each vehicle frame rail.
2. Secure each side with two l/2” x l-1/2” bolts, flat washers, and locknuts. Install flat washers against vehicle frame.
AS VIEWED FROM
F
DRILL
DRIVER SIDE 112” X i-112” BOLT
112” x
518” x
Shown)
LINK ARMS AS VIEWED FROM DRIVER SIDE Fasten a link arm between each pair of link arm lugs with one 3/4” x 3-l/4” grade 5 rivet and cot- ter pin on each side.
BUMPER
1. Reinstall bumper to original position using exist- 3/4” x 3-l/4”
ing fasteners.
2. The air deflector may require notching for clear- ance of link arm lugs, or it may be removed from the vehicle. If reinstalling deflector, use ex- isting fasteners. If deflector is removed from ve- hicle, retain deflector and fasteners and reinstall whenever the snowplow mount is removed from vehicle.
TIGHTEN ALL BOLTS TO CORRESPONDING TORQUE CHART VALUES.
AUTION: During electrical installation, THE LONG BATTERY GROUND CABLE (no stripe) MUST BE GROUNDED TO THE NEGATIVE BATTERY TERMINAL.
tlARNESS KIT SELECTION
For DUAL replaceable bulb type HB-5 headlamps, use box no. 61540 Headlamp Kit g-Pin and 61590 Harness Kit HB-5 S-Pin -A.
NOTE: After 5 to 10 hours of snowplow usage, retorque all mount assembly fasteners.
Plow may be removed from vehicle for installation of electrical components.
Form No. 13601 -4-
Solenoid Control INSTALLATION INSTRUCTIONS
1. Align dash bracket hole shown in diagram to end hole of control bracket.
NOTE: Top flange of control bracket may be re- versed in dash bracket from position shown in dia- gram. Attach with one #8 x 3/8” hex head thread cutting screw and lock washer on each side.
SOLENOID CONTROL BRACKET
CABLE CLAMP
2.
3.
4.
Use top holes in dash bracket (see diagram) as a template to drill a g/64” hole in each side of control bracket. Secure dash bracket to control bracket with a second screw and #8 x 518” HEX
lock washer in each side. HEAD TAPPIN
Secure solenoid control to control bracket with two #8 x 518” hex head tapping #lO X 1” SHEET screws.
(4) 90388 Move seat forward and 4 wheel drive lever S,. LOCK WASH-
THREAD CUTTING TAPPING SCREW
DASH BRACKET OLE SEE STEP 2 ASH BRACKET OLE SEE STEP 1
toward seat. Locate control and bracket ERS (4) 91242 assembly on floor tunnel so that it does not interfere with the operation of vehicle controls. Mark this location.
Remove control bracket from dash bracket.
Place dash bracket in marked location. Use dash bracket as a template to drill four l/8” holes in tunnel.
IC AUTION: Check for clearance before drilling holes. Secure dash bracket to tunnel with four #IO x 1” tapping screws and lock washers.
7. Reassemble control bracket to dash bracket. Bend top flange of control bracket to desired position.
8. Secure harness to control bracket with cable clamp and one #8 x 3/8” hex head thread cutting screw.
Installation instructions continue on next page.
HARNESS, SOLENOID CONTROL & MOTOR RELAY INSTALLATION DIAGRAM
Vehicle Underhood INSTALLATION INSTRUCTIONS
22” Red Cabl Optional Reversed
Hydraulic System ON/OFF Switch
Ground to Battery Negative Post #8 X 3/8” Screw (On Rev IO & Later Vehicle Harnesses)
Cable Assembly - Vehicl (Long Battery Cable Assem
Vehicle Harness
Grill Connectors (Mounted or Passed Through Grill)
(Apply dielectric grease to pin cavities)
iector
Self-Stripping Connector (Blue)
Vehicle Wire Controlled by Ignition (key) Switch
Form No. 13601 -5-
A ARNING: The symbol at left identifies a safety warning that indicates a po- tentially hazardous situation that, if not avoided, could result in death or se
rious personal injury.
VEHICLE HARNESS AND MOTOR RELAY Except as noted, parts to be installed are found in the hydraulics box.
C AUTION: To prevent corrosion on all under-hood electrical connections, use dielectric grease to fill receptacles and lightly coat ring terminals and blades before assembling,
or lightly coat the connections after assembling.
1. Identify wires for the parking lamp and the turn signals on both sides of the vehicle. Attach a black self-strip- ping bullet receptacle connector (found in harness kit) to each of these three wires.
2. Remove NEGATIVE battery cable from battery.
AW ARNING: Electrical shock hazard. Disconnect battery before beginning electrical installation.
3. Find a location for the motor relay where it will be protected from road splash and will be within 18” of the vehi- cle primary battery. NOTE: Motor relay terminals must be up or horizontal. Using the motor relay mounting plate as a template, drill two g/32” holes, and mount motor relay to holes using l/4” x 3/4” bolts, flat washers, and locknuts.
4. Route 22” red battery cable between a large motor relay terminal and the POSITIVE battery terminal avoiding sharp edges, and hot or moving parts. Attach cable to motor relay terminal with a lock washer and 5/l 6”-24 jam nut. Attach cable to battery POSITIVE terminal with existing terminal fastener. 1996 & Later-The original equipment battery terminal clamp bolt is not long enough to secure the hydraulic unit battery cables. Remove the original cap screw and replace it with the items indicated in the diagram below (found in the mount box).
Furnished 6mm Nut and 3/16” Plain Washer Vehicle Positive or Negative
Bend Tabs Out to Remove Orginal Cap Screw;
Bend Tabs Back After Installing Long Cap Screw
/- \ Battery Ctamp Furnished 6mm x 25mm Flange Head Cap Screw
or Hex Head Cap Screw with 3/i 6” Washer
5. Stretch rectangular openings of plug cover straps (found in harness kit) GRILL
over grill connector ends of long battery cable assembly (found in hydrau- CONNECTOR
lics box) and vehicle harness (found in harness kit). Place plug covers over PLUG COVER molds on harnesses.
6. Find a location on the vehicle grill on the battery side for mounting the battery cable grill connector. The best lo- cation is at least 1 O-1/2” from the center of the grill and at a convenient height for connecting the plow plugs. Allow grill connector of each harness to hang out in front of grill. Allow enough cable so it is easy to mate and remove connector. Secure with long cable ties (found in mount box).
7. Route battery cable through the grill at the selected location and through or around the radiator bulkhead to the motor relay avoiding sharp edges, and hot or moving parts.
Form NO. 13601 - 6-
8. Attach cable with red stripe to the unused large terminal on the motor relay and secure it with a lock washer and 5/l 6”~24 jam nut.
9. Route the battery cable without a stripe directly to the NEGATlVE battery terminal (carefully separate the two cables as needed to reach the battery ground). DO NOT attach cable to battery at this time.
10. Find a location in grill on driver side for mounting the vehicle harness (similar position to battery cable mount). See Steps 6 & 7 above for how to mount. Route vehicle harness through grill and around, or through radiator bulkhead (drill 5/8” hole if needed) into engine compartment.
11. Route the wires that break out of the vehicle harness to the area behind the driver-side headlamp. Route rest of harness to the firewall. Drill a 5/8” hole through the firewall in a convenient location away from sharp edges, and hot or moving engine parts.
IMPORTANT: On all vehicles with DRLs, insert fuse holder on pink wire of DRL Adapter Kit (PN 61584) through firewall first. Route end of pink wire with receptabies to area of driver-side headlamp.
Feed vehicle harness fuse holder through hole and then feed the plastic connector and harness through to the cab. Disassembling the fuse holder may make it easier to pass through 518” hole.
12. Route brown/red and orange/black (early revision harnesses have brown/red and black/orange wires) wire loom to motor relay. Early revision harnesses must be modified if the CabCommand control is being installed. (See instructions furnished with the CabCommand control.)
Attach the brown/red and orange/black (early revisions black/orange) wires small ring terminals to separate small terminals on motor relay using a lock washer and #I O-32 nut for each connection.
13. Route the orange/black wire with 3/8” ring terminal to the battery negative post DO NOT attach wire to battery at this time.
14. Inside the cab, route vehicle harness connector to solenoid or CabCommand control and couple the connec- tors together.
15. Reconnect vehicle ground cable to the NEGATIVE battery terminal. Attach the hydraulic unit black battery ca- ble and orange/black wire terminal to the negative clamp bolt as shown in the diagram on the previous page.
16. Locate an accessory wire capable of carrying 7 amps in addition to existing circuit loads and controlled by the ignition (key) switch. Route the vehicle harness SFE-6* fuse holder red wire to this location and trim off any ex- cess length of wire (keep fuse holder in system). If used, DRL pink wire requires 0.4 amps.
Open the blue, self-stripping connector and place the end of the red wire against the inner groove stop (end of wire must not extend from the closed connector), and the accessory wire in the outer groove. Close connector over the wires using a pliers and snap the locking tab in place. Repeat with DRL pink wire.
* Early style harnesses have a lo-amp fuse which must be replaced with SFE-6 fuse for CabCommand control.
REMINDER: To prevent corrosion on all under-hood electrical connections, use dielectric grease to fill receptacles, including grill connectors, and lightly coat ring terminals and blades before assembling or lightly coat connections after assem- bling. --
DIELECTRIC GREASE -
Part Number - ---- _----
Form NO. 13601 -7-
DUAL VEHICLE HEADLAMP PLUG- IN HARNESS & HEADLAMP RELAY
REMINDER: Lubricate all receptacles and blades with dielectric grease before assembling. 1.
2.
3.
4.
5.
6.
7.
8. 9.
In the engine compartment behind the cjriver-side headlamp, insert wire bullets from vehicle harness into black bullet connectors (installed in step one of previous section) with brown wire to parking lamp wire on driver side, and gray wire to left turn signal wire on driver side. At the vehicle driver-side headlamp, remove the connector from the headlamp and couple matching connector with plug-in harness 3-wire male plug (plug-in harness found in harness kit). Attach plug-in harness headlamp connector to headlamp terminals. Route other end of plug-in harness along radiator bulkhead or over radiator shroud to curb-side headlamp. Re- move headlamp connector and couple matching connector with plug-in harness l-wire male plug. Attach plug- in harness headlamp connector to headlamp terminals. On the curb side, insert purple wire bullet from plug-in harness into vehicle turn signal black bullet connector installed in step one of the previous section. At the driver-side headlamp, insert the purple wire bullet from the vehicle harness into the purple wire recepta- cle on the plug-in harness. At driver-side headlamp, connect vehicle and plug-in harness wires with receptacles to the two headlamp re- lays (found in harness kit) as shown in the above diagram. (If vehicle has DRLs, replace brown wires with pink wire from DRL kit. Brown wires from vehicle harness are not used in DRL installations.)
Place grommet around vehicle harness and insert into firewall hole (also put a grommet in the hole in the ra- diator bulkhead if one was drilled). Use cable ties (found in harness kit) to secure harnesses, relays and wires away from sharp edges, and hot or moving engine parts and to prevent accidental grounding of connections.
Replace vehicle turn signal flasher with flasher furnished in harness kit. Lubricate terminal cavities of both grill connectors with dielectric grease. Give dielectric grease tube to vehicle owner for future lubrication of grill connectors.
Continued on next page.
FormNo. -8-
OPERATIONAL TESTS AND ADJUSTMENTS
OPERATIONAL TESTS AND ADJUSTMENTS Mount plow assembly to vehicle. (See label on back of blade or Owner’s Manual for mounting instructions.)
Filling Hydraulic Unit
1. Push lift channel all the way down. Filler Plug
2. Remove fill plug and fluid level plug.
3. Fill unit through fill plug hole until fluid runs out of fluid level hole. Replace both plugs.
Use: automatic transmision fluid (ATF) Dexron III to -10” F (-23” C), or F’uid Leve’ ‘lug WESTERN@ High Performance Fluid to -25” F (-32” C), or Texaco 1537 Aircraft Hydraulic Oil for temperatures below -25” F (-32” C).
4. Turn ignition (key) switch to the ON or ACCESSORY position.
5. Turn the control ON/OFF switch to the ON position.
6. Move control lever to angle left and angle right several times to remove air from Hydra-Turn@ rams. DO NOT raise blade. This may cause pump cavitation.
7. Refill unit with fluid following the procedure in Step 3 of this section.
8. Move the control lever as indicated on label to control the plow. Raise and lower plow several times to re- move air. Recheck fluid level according to Step 3 of this section.
Capacity: Solenoid ISARMATI? Mark llla reservoir l-3/4 quarts Equipped with 10” Hydra-Turn rams 2-318 quarts
ARNING: To prevent accidental movement of plow, always turn the sole- noid control to the OFF position when the mounted plow is not in use.
Blade Drop Speed Adjustment The quill on the top rear of the valve manifold (see diagram) adjusts blade drop speed.
Turn quill IN (clockwise) to decrease drop speed.
Turn quill OUT (counterclockwise) to increase drop speed.
NOTE: Turning quill too far in can slow raise time
Quill
I COUPLING LUG HEIGHT CHECK
Coupling Lug Height Check 1. Mount plow to vehicle (see label on back of blade or Owner’s Manual
for mounting instructions). Add recommended ballast as found in se- lection list.
Center Of
Coupling 2. Lift plow and move vehicle a minimum of 10 feet. Lower blade.
3. After step 2, with blade on level surface, slack in lift chain, and rear ballast located behind rear wheels, the center of coupling lug holes
,2lFE)\
(hitch pin shaft) to level surface should measure 9-l/2” to 10-l/2”. To obtain height, adjust spreader position. 9-112” To 10-l/2”
1
4 Level Surface NOTE: Coupling height must be 9-112” minimum to al- low stand to be pinned to lift frame. Height With Plow Attached
And Blade On Level Surface
4. Adjust chain slack with plow mounted to vehicle and lift channel pushed all the way down. To adjust, remove chain from hook. Straighten chain and pull tight. Rehook it to lift channel. After it is hooked, it will have the correct amount of slack for blade “float.” DO NOT remove chain from lift channel when removing plow from vehicle.
Form No. 13601 -9-
FINAL HYDRAULIC INSPECTION
Final Hydraulic Inspection 1. Make sure all fasteners and hydraulic and electrical connections are tight. 2. Check ram packing nuts for oil leakage. If any leakage is observed, tighten the packing nut l/4 turn after you
feel the nut contact the packing. Do not overtighten - over-tightening affects cylinder operation and shortens the life of the packing. A short period of normal operation will allow chevron packings to become saturated, and leakage will normally stop.
VEHICLE LIGHTING CHECK
Vehicle Lighting Check 1. Check the operation of vehicle and plow lights with plow mounted to vehicle and both plow plugs connected.
Turn signals and parking lamps
Parking lamps ON Both vehicle and plow parking lamps should be on at the same time. Right Turn Signal ON Both vehicle and plow right turn signal lamps should flash at the same time. Left Turn Signal ON Both vehicle and plow left turn signal lamps should flash at the same time.
Headlamps Move vehicle headlamp switch to the ON position. Connecting and disconnecting the g-pin plow plug from the grill connector should switch between vehicle and plow headlamps as follows:
g-pin plow plug DISCONNECTED Vehicle headlamps should be on, plow headlamps off. g-pin plow plug CONNECTED Plow headlamps should be on, vehicle headlamps off.
Dimmer switch should dim whichever headlamps are operating. The high beam indicator on the dash should light when either set of headlamps is on high beam.
Solenoid or CabCommand Control g-pin vehicle harness revision 10 and later or g-pin vehicle harnesses-earlier revisions modified for CabCommand control:
The control indicator light should light whenever the control ON/OFF switch and the ignition (key) switches are both in the ON position. The plow plugs do not need to be connected to the grill connectors.
Solenoid Control used with earlier revision harnesses g-pin revision 7, 8, or 9 vehicle harnesses:
The control indicator light should light whenever the control ON/OFF switch and the ignition (key) switches are both turned ON and the plow plugs are connected to the grill connectors.
g-pin vehicle harnesses-all earlier revisions: The indicator light will also light when the control and ignition (key) switches are on the plow plugs are disconnected. If the parking lights are turned on (with plow plugs disconnected), the indicator light will go out.
2. Connect plow plug to grill connector. Raise plow and aim plow headlamps according to SAE J599 Lighting In- spection Code (See Service Bulletin SP 608) and any applicable federal, state, or local regulations.
3. Check aim of vehicle headlamps with plow removed. 4. When plow is removed from the vehicle, install plug covers on grill connectors and insert the plow plugs into
the boot on the hydraulic unit.
NOTE: After 5 to 10 hours of snowplow usage, retorque all mount assembly fasteners.
Form No. 13601 - 10 -
0” Solenoid Control - Q-Pin Vehicle Harness Revision 10 & Later - The control indicator light will light whenever the control ON/OFF switch and the 3 ignition (key) switch are both turned ON. The plow plugs and grill connectors do not need to be connected for the control light to be on. i: UnilllMiitt~
Vehicle harnesses - 9 pin, P.N. 61437 rev. 7 or 12 pin, P.N. 61557, rev. 5 and later-The indicator Vehicle harnesses with revision numbers prior to listed revisions at right - The indicator light will also light on the solenoid control will only light when the plow is attached to the vehicle and the ignition be on when the control and ignition (key) switches are ON and the plow plugs are disconnected. If switch and control on/off switch are both turned on. the parking lights are turned on (with plow plugs disconnected), the indicator light will go out.
LEVER, SPRING &ACTUATOR Parts listed above may be found in the following assembly.
KIT (Style 2) 61547 1 PARTS BAG
1 1 1 1
1 1 1 2 2 1 4 4 1 5 4 1 1
2 2 2 2 1 2 2 2 1 1
2 1
SPRING -CONICAL PC BOARD ASSY MOLEX (Style 2) BASE #6-i 9X3/8 SL HXW TFTS HILO #8-l 8X5/8 SL HXW TFTS HILO CONTROL BRACKET #l OX1 SL PN TFTS TY AB BZP #lO SP LK WASHER BP0 CABLE CLAMP #8-32X3/8 SL HXW TCTS TY T BP 85
#8 SP LK WASHER BP Found in Mount Box No. 61820 CABLE ASSEMBLY -VEHICLE 85 61536 4 CABLE TIE - LONG
. 91242
. 91402
. 91202 92842
;2511 90002 91101 91331 56099 49326
RELAY-SOLENOID HYDRAULIC 90 56080 1 DASHBRACKET SYS Parts listed above may be found in the following assembly.
#lO SP LK WASHER BP0 6 1826 1 #l O-32 HX NUT ZP
BOLT BAG ASSY (61820)
5/16 SP LK WASHER ZP Indented part numbers are included in the assembly under which they are listed. Quantities shown are included with the assembly.
5/16-24 HX JAM NUT BATTERY CABLE 22” RED Abbreviaiions
1/4-20X3/4 HX CS G2 ZP ASSY Assembly SL slotted
l/4 PLAIN WASHER TY A STD ZP BP Black Phosphate SP Spring BP0 Black Phosphate &Oil SPDT Single Pole Double Throw
i/4-20 PT HX LK NUT NYIS ZP BZP Black Zinc Plate STD Standard cs Capscrew SYS System
DIELECTRIC GREASE TUBE G Grade TCTS Thread Cutting Tapping HD
WESTERN DIELECTRIC GREASE Heavy Duty Screw
L&v Hex TFTS Thread Forming Tapping
TUBE (2 ounce) Hex Washer Screw
LK Lock TY Type
62 66130 RUBBER GROMMET 63 59114 SELF STRIP WIRE CONNECTOR Parts listed above may be found in one of these assemblies.
NYIS Nylon Insert U UniMountBSystem PC Printed Circuit WI With PN Pan ZP Zinc Plate P-f Prevailing Torque
9- 56
I Mount Assembly Box No. 61820 Harness Kit Box No. 61590 Hydraulics Box No. 56365 PARTS DIAGRAM & LIST
65
56368 i CARTON ASSY LOOSE PARTS U . 56367 1 BOLT BAG ASSY LARGE U . . 56358 1 BOLT BAG SMALL U AA
